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XJ 1100: Melted Stator Connector. Now no start..

Discussion in 'XJ Technical Chat' started by knitt31, May 4, 2015.

  1. knitt31

    knitt31 New Member

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    Hey everyone,
    First post here. Working on my friend's 1982 XJ1100. We had gas leak down into the case and eat the seal on the ignition side crankshaft seal, so it ended up dropping all of the oil. (in the driveway, not while it was running). We pulled and dipped the carbs, new orings, and rebuild the petcocks so the gas leak has been solved. Tonight we were syncing the carbs in high hopes of having it back on the road again. During this, I noticed smoking from a connector above the airbox. Turned the bike off to find out the connection was pretty melted. We had the tank sort of propped up in order to adjust carbs, so there's a chance it pinched and shorted something, but I can't figure out what. After trying to start the bike again, we're getting nothing but lights. No started, no solenoid click. I believe the melted connector in question is the three white wires between the stator and R/R. In my mind, this would kill the charging, but this shouldn't keep the starter from turning?? Not sure where to go from here. Any wisdom is appreciated.

    Also, there was this strange wire hanging (not connected) down behind the rear master. I have no idea what it's for??
    <a href="http://s1241.photobucket.com/user/knitt31/media/Mobile Uploads/20150504_182416_zpspznhsluq.jpg.html" target="_blank"><img src="http://i1241.photobucket.com/albums/gg513/knitt31/Mobile Uploads/20150504_182416_zpspznhsluq.jpg" border="0" alt=" photo 20150504_182416_zpspznhsluq.jpg"/></a>
    <a href="http://s1241.photobucket.com/user/knitt31/media/Mobile Uploads/20150504_182917_zps44xdb0po.jpg.html" target="_blank"><img src="http://i1241.photobucket.com/albums/gg513/knitt31/Mobile Uploads/20150504_182917_zps44xdb0po.jpg" border="0" alt=" photo 20150504_182917_zps44xdb0po.jpg"/></a>
     
  2. Toomanybikes

    Toomanybikes Well-Known Member

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    That might be the wire harness ground wire. As far as the stator plug Honda makes a stator plug repair kit. Check with local dealer I think if memory is correct its 31105-ML8-305
    ( was a parts manager in a former life)
    Toomany
     
  3. Stumplifter

    Stumplifter Well-Known Member

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    Hey Knitt, welcome to the club.
    We might be neighbors. I'm in the Sherman Park area, near St. Joe's hospital.

    I can't help with anything electric. To add to what Toomany said, there is The Shop (http://www.theshopmilwaukee.com ) in Bayview that is a good local resource for older Japanese bikes (spoiler alert- they have valve shims there for a good price). For XJ specific components clicking on the XJ4Ever icon in the upper right hand corner will bring you much happiness.

    There is a lot of wisdom here so keep asking questions if you get stuck.
     
  4. FJ111200

    FJ111200 Active Member

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    First two pictures you are correct about it being the connector from the alternator/generator to the reg/rec, and the second two pictures look like the battery electrolyte level sensor.
    The starter won't turn if the battery has been flattened or run down due to the melted connector from the reg/rec and alternator.
     
  5. Toomanybikes

    Toomanybikes Well-Known Member

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    Yes it is for battery not ground wire as I had stated. I didn't look at the photo
     

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